Paper textile yarn package and blank

ABSTRACT

A textile paper yarn package that has a hollow body with opposing open ends, and formed of a paper blank having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body. The outer end edge of the paper blank forms a lap seam that extends in a spiral shape around a predetermined extent of the exterior of the body as it extends between the opposing open ends of the body of the package.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to a textile yarn package, and more specifically to a textile yarn package, that is formed from a paper blank having a novel shape that results in substantial savings in paper usage. While the invention disclosed in this application has utility on a number of different types of yarn carriers, for purposes of illustration the invention will be described with reference to a tubular textile yarn package, which is formed of pressed paper and has a generally frusto-conical shape. While cones come in numerous configurations, one common cone is a cone, which has an angle of taper of 5 degrees, 57 minutes.

The principal constituent part of such packages is the paper itself. Thus, the amount of paper used to fabricate a package has a significant effect on the cost of the package. Packages are manufactured by cutting paperboard into a blank having a predetermined shape from which the package will be produced. To produce cones, the paperboard is cut according to the size, shape and conicity required by the customer. The cut edges are ground, then adhesive is applied to the paper and the paper is wound onto a spindle having the same conicity. Most cones are formed with either three, four or five wraps of the paper around the spindle. The nose of the cone is formed and the cones are dried and rough finished. The base is finished and features such as anti-nesting ribs or notches may be formed in the base. Quality control processes, such as weighing and sorting are carried out, as well as, printing patterns, colors or customer information onto the exterior and/or the interior of the cones. Of course, in certain instances the order of the manufacturing steps may vary.

Traditional manufacturing techniques result in a package having an exterior seam that extends along the package in longitudinal alignment with the axis of rotation. See FIG. 1. This construction results from the use of a curved, relatively symmetrical paper blank, as shown in FIG. 2. This construction results in several disadvantages. For example, due to the conventional shape of the paper blanks, a significant amount of paper is wasted as the blanks are cut from the sheet of paper. In addition, the conventional outer seam on the package may create unbalanced rotation of the cone on various operating machinery. Other disadvantages are discussed below.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a paper textile yarn package that uses less paper in its formation than conventional yarn packages.

It is another object of the invention to provide a paper textile yarn package that is more precisely balanced.

It is another object of the invention to provide a paper textile yarn package with enhanced resistance to shape deformation.

It is another object of the invention to provide a paper textile yarn package with reduced waste.

These and other objects and advantages of the invention are achieved by providing a textile paper yarn package that includes a hollow body having opposing open ends and formed of a paper blank having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, wherein the outer end edge of the paper blank forms a lap seam that extends in a spiral around a predetermined extent of the exterior of the body as it extends between the opposing open ends of the body of the package.

According to one embodiment of the invention, the yarn package is a cone.

According to another embodiment of the invention, the lap seam extends in a spiral shape around the exterior of the body and defines at least a 90-degree arc.

According to another embodiment of the invention, the lap seam extends in a spiral shape around the exterior of the body and defines a 270-degree arc.

According to another embodiment of the invention, a textile paper yarn cone is provided that includes a hollow body having opposing open ends and is formed of a paper blank having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, wherein the outer end edge of the paper blank forms a lap seam that extends in a spiral around a predetermined extent of the exterior of the body of at least 90 degrees as it extends between the opposing open ends of the body of the package.

According to another embodiment of the invention, the package has an angle of taper of at least 1 degree.

According to another embodiment of the invention, the package has an angle of taper of at least 1 degree and no more than 10 degrees.

According to another embodiment of the invention, the package has an angle of taper selected from the group of angles consisting of 1 degree, 51 minutes; 3 degrees, 30 minutes; 3 degrees, 51 minutes; 4 degrees, 20 minutes; 5 degrees, 32 minutes; 5 degrees, 57 minutes; 7 degrees, 22 minutes; 9 degrees, 15 minutes; and 9 degrees, 36 minutes.

According to another embodiment of the invention, a textile paper yarn cone blank is provided that includes a paper strip having inner and outer curved sides and opposed end edges, wherein the curved outer side defines an arc of at least 50 degrees and no more than 120 degrees, and further wherein, when wound onto a conical spindle, forms a textile paper yarn package comprising a hollow body having opposing open ends having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, the outer end edge of the paper blank forming a lap seam that extends in a spiral shape around a predetermined extent of the exterior of the body as it extends between the opposing open ends of the body of the package.

According to another embodiment of the invention, the blank has opposing end edges that extend at an angle of between 50 degrees and 120 degrees relative to each other.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

FIG. 1 is a side elevation of a conventional paper textile yarn cone, indicating the paper end seam extending along the longitudinal axis of the cone;

FIG. 2 is a plan view of two prior art paper blanks from which cones such as the one shown in FIG. 1 are manufactured;

FIG. 3 is a side elevation of a paper textile yarn cone according to one embodiment of the invention, indicating the paper end seam extending in a spiral around the exterior of the cone;

FIG. 4 is a top plan view of the paper textile cone of FIG. 3 showing the spiraled paper end seam also shown in FIG. 3;

FIG. 5 is a plan view of two other prior art paper blanks from which cones such as the one shown in FIGS. 3 and 4 are manufactured;

FIG. 6 is a plan view of two novel paper blanks from which cones according to an alternative embodiment of the invention are manufactured; and

FIG. 7 is a plan view of two novel paper blanks from which cones according to a further alternative embodiment of the invention are manufactured.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1 and 2, a paper textile cone 10, as shown in FIG. 1, includes an elongate, frusto-conical hollow body 11 defining a relatively small diameter nose 12 and an opposed, relatively large diameter base 13. The cone 10 is formed such that the seam 14 representing one end of a paper blank 15 from which it is formed extends along the longitudinal axis of the cone 10, as shown. The blank 15 has opposing end edges 15A, 15B. Upon fabrication of the cone 10, the end edge 15A forms a lap seam 14 on the exterior of the cone 10, and the end edge 15B forms a lap seam on the interior of the cone 10. Even though this seam 14 and the outer surface of the cone 10 are sanded to feather the lap seam 14 into the plane of the adjacent area of the body 11 of the cone 10, the placement of the lap seam 14 along the longitudinal axis of the cone 10 creates a slight asymmetry along its length that can cause unbalanced rotation when being rotated at high speed. This, in turn, can cause undesirable variation in the very precise wind pattern of yarn being wound onto the cone 10.

The shape of the paper blank 15 from which cone 10 is fabricated is shown in FIG. 2 and is used to fabricate a 5 degree, 57 minute, 68-170 mm, 4 lap cone. Note that the angle defined by the intersection of the opposing ends 15A, 15B is approximately 160 degrees. Note also that the arc of the blank 15 defines a segment of a relatively small diameter circle. As can be seen in FIG. 2, a relatively large waste area is created between the two blanks 15 and to each side of the blanks 15. A similar prior art blank is shown in FIG. 5.

Referring now to FIG. 3, a cone according to one preferred embodiment of the invention is shown at reference numeral 20. Cone 20 includes an elongate, frusto-conical hollow body 21 defining a relatively small diameter nose 22 and an opposed, relatively large diameter base 23. The cone 20 is formed such that the lap seam 24 representing one end edge of the paper blank extends in a spiral from the base 23 around the body 21 to the nose 22 of the cone 10, as shown. In the particular embodiment of FIG. 3, the spiral lap seam 24 extends around approximately 270 degrees of the body 21 of the cone 20 between the nose 22 and the base 23. See also FIG. 4. The longer length of the lap seam 24 and its spiral progression around the body 21 of the cone 20 tends to minimize any asymmetry in the cone 20. As used in this application, the term “spiral” is used in a general sense to mean any three-dimensional curve that turns around an axis at a constant or continuously varying distance while moving parallel to an axis, and may also be termed a “helix” and a “conic helix.”

The extent of the spiral lap seam around a specific cone depends on the angle of taper of the cone and the configuration of the end edge of the blank that resides on the outer surface of the cone.

Examples of paper blanks in accordance with the disclosure of the invention and shaped to provide savings in paper and achieving the other advantages are shown in FIGS. 6 and 7. These blanks are indicated at reference numerals, 40 (3 degree, 51 minute, 63-170, 4 lap) and 50 (5 degree, 57 minute, 68-170, 3 lap), of FIGS. 6 and 7, respectively. In each case, note that the arc of the respective blanks 40 or 50 is relatively shallow and therefore defines a segment of a larger diameter circle. As a consequence, the area between adjacent blanks is smaller and thus results in less wasted paper. Note also the straight, aligned end edges 40B and 50B, and the resulting reduction of wasted paper.

As shown in FIG. 6, the angle defined by the intersection of the opposing ends 40A, 40B is approximately 72 degrees. As shown in FIG. 7, the angle defined by the intersection of the opposing ends 50A, 50B is approximately 90 degrees. In each case, the angle of intersection is significantly less than in prior art blanks, such as blank 15 of FIG. 2 and blank 30 of FIG. 5.

Cones fabricated using paper blanks according to the disclosure of this application require less paper, weigh less, produce less waste, have greater strength and exhibit improved balance. Certain of these advantages are demonstrated with reference to the Tables set out below:

TABLE 1 PRIOR ART CONE (5 degree, 32 minute) Weight (g) Strength (kg) Sample 1 43.3 41.329 Sample 2 43 39.62 Sample 3 43.9 39.459 Sample 4 43.3 41.479 Sample 5 43.1 41.898 Average 43.32 40.757 Min 43 39.459 Max 43.9 41.898

TABLE 2 NOVEL CONE (5 degree, 32 minute) Weight (g) Strength (kg) Sample 1 43.7 40.478 Sample 2 41.237 44 Sample 3 43.8 43.188 Sample 4 43.8 43.373 Sample 5 43.8 38.873 Average 43.2674 41.9824 Min 41.237 38.873 Max 43.8 44

TABLE 3 PRIOR ART CONE NOVEL CONE TWR 1.35 ≈1.17 Cone Weight 43.32 43.2674 Pattern Weight 58.482 50.622858 Paper Saving 13%

As shown in Table 1, five conventional, prior art cones were tested for weight and strength. To determine strength, pressure is applied to the wall of the cone until it breaks. The cone is placed on a support having the same taper, so it lies horizontally and a steel plate makes contact and applies pressure until breakage or crushing, at which point a reading is determined in Kg.

The cones of Table 1 were manufactured using blanks such as the type illustrated in FIGS. 2 and 5. Note the average weight—43.32 g. and the average strength—40.757 Kg.

As shown in Table 2, cones using blanks such as the type illustrated in FIGS. 6 and 7 were manufactured and tested in the same manner as those in Table 1. Note that the while the average weight of the novel cones of FIG. 2 was slightly less—43.2674 g; the novel blank produced a stronger cone more resistant to deformation—41.9824 Kg.

From Table 3, it can be seen that while prior art cone weight and the novel cone weight are similar, the weight of the blank from which the novel cone is manufactured is dramatically lower—50.62 g vs. 58.48 g for the prior art cone. This provides a clear indication of substantially less wasted paper for the novel cone on the order of 13 percent, with a Theoretical Waste Ratio (TWR) of 1.17 vs. 1.35 for the prior art cone.

In addition, testing demonstrates that the “roundness” of cones according to the disclosure of this application is improved, and thus balance and uniformity. As shown in Table 4 below, conventional cones when tested were “out of round” by about 0.70 mm, whereas cones according to the novel cones of this application test as being “out of round” by only 0.48 mm. This test is performed by using a standard measurement machine to contact the cone at a specified distance, for example, 15 mm, from the base. The machine contacts the entire circumference of the cone at the 15 mm distance to determine a profile of the section. Then, the machine calculates the maximum circle that can be placed inside the profile (ID) and the minimum circle that can be placed outside the profile (OD). Roundness is therefore defined as the difference between the radius of the circles defined by the ID and OD. As noted above, therefore, the difference between the ID and OD of the novel cone is 0.48 mm vs, 0.70 mm for the conventional cone,

TABLE 4 ROUNDESS PRIOR ART CONE NOVEL CONE Sample 1 0.81857 0.49925 Sample 2 0.70494 0.52731 Sample 3 0.70475 0.42679 Sample 4 0.55798 0.51955 Sample 5 0.83247 0.43761 Average 0.732742 0.482102 Min. 0.55798 0.42679 Max. 0.83247 0.52731

A textile paper yarn package according to the invention has been described with reference to specific embodiments and examples. Various details of the invention maybe changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. 

1. A textile paper yarn package, comprising a hollow body having opposing open ends, and formed of a paper blank having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, wherein the outer end edge of the paper blank forms a lap seam that extends in a spiral shape around a predetermined extent of the exterior of the body as it extends between the opposing open ends of the body of the package.
 2. A textile paper yarn package according to claim 1, wherein the yarn package is a cone.
 3. A textile paper yarn package according to claim 2, wherein the lap seam that extends in a spiral around the exterior of the body defines at least a 90-degree arc.
 4. A textile paper yarn package according to claim 2, wherein the lap seam that extends in a spiral around the exterior of the body defines a 270-degree arc.
 5. A textile paper yarn cone, comprising a hollow body having opposing open ends, and formed of a paper blank having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, wherein the outer end edge of the paper blank forms a lap seam that extends in a spiral around a predetermined extent of the exterior of the body of at least 90 degrees as it extends between the opposing open ends of the body of the package.
 6. A textile paper yarn cone according to claim 5, wherein the lap seam that extends in a spiral around the exterior of the body defines a 270-degree arc.
 7. A textile paper yarn cone according to claim 5, and having an angle of taper of at least 1 degree.
 8. A textile paper yarn cone according to claim 5, and having an angle of taper of at least 1 degree and no more than 10 degrees.
 9. A textile paper yarn cone according to claim 5, and having an angle of taper selected from the group of angles consisting of 1 degree, 51 minutes; 3 degrees, 30 minutes; 3 degrees, 51 minutes; 4 degrees, 20 minutes; 5 degrees, 32 minutes; 5 degrees, 57 minutes; 7 degrees, 22 minutes; 9 degrees, 15 minutes; and 9 degrees, 36 minutes.
 10. A textile paper yarn cone blank, comprising a paper strip having inner and outer curved sides and opposed end edges, wherein the curved outer side defines an arc of at least 50 degrees and no more than 120 degrees, and further wherein, when wound onto a conical spindle, forms a textile paper yarn package comprising a hollow body having opposing open ends having an outer end edge positioned on an exterior surface of the body and an inner end edge positioned on an interior surface of the body, the outer end edge of the paper blank forming a lap seam that extends in a spiral around a predetermined extent of the exterior of the body as it extends between the opposing open ends of the body of the package.
 11. A textile paper yarn package blank according to claim 10, wherein the lap seam that extends in a spiral around the exterior of the body defines at least a 90-degree arc.
 12. A textile paper yarn package blank according to claim 10, wherein the lap seam that extends in a spiral around the exterior of the body defines a 270-degree arc.
 13. A textile paper yarn package blank according to claim 10, and having opposing end edges that extend at an angle of between 50 degrees and 120 degrees relative to each other. 